Slip ring assembly for surgical instrument

ABSTRACT

A surgical instrument includes a body assembly, a shaft assembly extending distally from the body assembly along a shaft axis, and an end effector at a distal end of the shaft assembly. The shaft assembly includes an outer tube configured to rotate relative to the body assembly about the shaft axis. The surgical instrument further includes a slip ring assembly configured to enable electrical communication between the shaft assembly and the body assembly while permitting relative rotation therebetween. The slip ring assembly includes a first electrical contact supported by the outer tube, and a second electrical contact electrically coupled with the first electrical contact and positioned radially outward of the outer tube. The first electrical contact is configured to rotate with the outer tube about the shaft axis relative to the second electrical contact while the first and second electrical contacts remain electrically coupled.

This application is a continuation of U.S. patent application Ser. No.15/934,190, entitled “Slip Ring Assembly for Surgical Instrument,” filedMar. 23, 2018, and issued as U.S. Pat. No. 10,631,861 on Apr. 28, 2020,the disclosure of which is incorporated by reference herein.

BACKGROUND

Endoscopic surgical instruments may be preferred over traditional opensurgical devices in certain instances to create a smaller surgicalincision in the patient and thereby reduce the post-operative recoverytime and complications. Examples of endoscopic surgical instrumentsinclude surgical staplers. Some such staplers are operable to clamp downon layers of tissue, cut through the clamped layers of tissue, and drivestaples through the layers of tissue to substantially seal the severedlayers of tissue together near the severed ends of the tissue layers.Merely exemplary surgical staplers are disclosed in U.S. Pat. No.7,404,508, entitled “Surgical Stapling and Cutting Device,” issued Jul.29, 2008; U.S. Pat. No. 7,721,930, entitled “Disposable Cartridge withAdhesive for Use with a Stapling Device,” issued May 25, 2010; U.S. Pat.No. 8,408,439, entitled “Surgical Stapling Instrument with AnArticulatable End Effector,” issued Apr. 2, 2013; U.S. Pat. No.8,453,914, entitled “Motor-Driven Surgical Cutting Instrument withElectric Actuator Directional Control Assembly,” issued Jun. 4, 2013;U.S. Pat. No. 9,186,142, entitled “Surgical Instrument End EffectorArticulation Drive with Pinion and Opposing Racks,” issued Nov. 17,2015; and U.S. Pat. No. 9,795,379, entitled “Surgical Instrument withMulti-Diameter Shaft,” issued Oct. 24, 2017. The disclosure of each ofthe above-cited U.S. patents is incorporated by reference herein.

While the surgical staplers referred to above are described as beingused in endoscopic procedures, such surgical staplers may also be usedin open procedures and/or other non-endoscopic procedures. By way ofexample only, a surgical stapler may be inserted through a thoracotomy,and thereby between a patient's ribs, to reach one or more organs in athoracic surgical procedure that does not use a trocar as a conduit forthe stapler. Of course, surgical staplers may be used in various othersettings and procedures.

While several surgical instruments and systems have been made and used,it is believed that no one prior to the inventors has made or used theinvention described in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an exemplary surgical instrumenthaving a handle assembly and an interchangeable shaft assembly;

FIG. 2 depicts a partially exploded perspective view of the surgicalinstrument of FIG. 1, showing the interchangeable shaft assemblyseparated from the handle assembly;

FIG. 3A depicts a side elevational view of the surgical instrument ofFIG. 1, with a body of the handle assembly omitted, showing a closuretrigger of the handle assembly in an unactuated position;

FIG. 3B depicts a side elevational view of the surgical instrument ofFIG. 1, with a body of the handle assembly omitted, showing a closuretrigger of the handle assembly in an actuated position;

FIG. 4 depicts another perspective view of the surgical instrument ofFIG. 1 in a separated state, showing additional details of a distal endof the handle assembly and a mating proximal end of the interchangeableshaft assembly;

FIG. 5 depicts another perspective view of the surgical instrument ofFIG. 1 in a separated state, with certain components of the handleassembly and the shaft assembly omitted to reveal components of a firingsystem;

FIG. 6 depicts an exploded perspective view of an end effector of thesurgical instrument of FIG. 1, in combination with certain components ofthe firing system;

FIG. 7 depicts a perspective view of a proximal portion of theinterchangeable shaft assembly of the surgical instrument of FIG. 1,with a nozzle of the shaft assembly omitted to reveal details of aninternal slip ring assembly;

FIG. 8 depicts a side elevational view of another exemplary end effectorhaving a plurality of sensors;

FIG. 9 depicts a perspective view of a proximal portion of the shaftassembly of the surgical instrument of FIG. 1, showing an exemplaryalternative slip ring assembly housed within the nozzle, with an upperportion of the nozzle omitted from view and with a sleeve of the slipring assembly partially sectioned to expose internal features;

FIG. 10 depicts a partial side cross-sectional view of the slip ringassembly and adjacent components of the shaft assembly of FIG. 9;

FIG. 11 depicts an end cross-sectional view of the slip ring assemblyand adjacent components of the shaft assembly of FIG. 10, taken alongline 11-11 of FIG. 10;

FIG. 12 depicts a perspective view of a contact block with brushcontacts of the slip ring assembly of FIG. 9;

FIG. 13A depicts a side cross-sectional view of the contact block and acontact sleeve of the slip ring assembly of FIG. 9, showing the contactblock and the contact sleeve in a pre-assembled state;

FIG. 13B depicts a side cross-sectional view of the contact block andthe contact sleeve of FIG. 13A, showing the contact block and thecontact sleeve in an assembled state;

FIG. 14 depicts a side cross-sectional view of a portion of the contactsleeve of the slip ring assembly of FIG. 9;

FIG. 15 depicts an enlarged side cross-sectional view of the contactsleeve of the slip ring assembly and a closure tube of the shaftassembly of FIG. 9, showing a fluid bridge formed between adjacentelectrical contacts of the contact sleeve;

FIG. 16 depicts an enlarged side cross-sectional view of the contactsleeve and the closure tube of FIG. 15, showing an electricallyinsulating element positioned between adjacent electrical contacts ofthe contact sleeve;

FIG. 17 depicts a cutaway perspective view of a channel of the endeffector of FIG. 6, schematically showing an electrical connectorcoupled to the channel;

FIG. 18 depicts a perspective view of a first exemplary configuration ofthe electrical connector of FIG. 17;

FIG. 19 depicts a side sectional view of another exemplary configurationof the electrical connector of FIG. 17;

FIG. 20A depicts a side cross-sectional view of another exemplaryconfiguration of the electrical connector of FIG. 17, showing theelectrical connector in an open state;

FIG. 20B depicts a side cross-sectional view of the electrical connectorof FIG. 20A, showing the electrical connector in a partially closedstate; and

FIG. 20C depicts a side cross-sectional view of the electrical connectorof FIG. 20B, showing the electrical connector in a fully closed state.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

For clarity of disclosure, the terms “proximal” and “distal” are definedherein relative to a surgeon, clinician, or other operator, grasping asurgical instrument having a distal surgical end effector. The term“proximal” refers to the position of an element arranged closer to thesurgeon, and the term “distal” refers to the position of an elementarranged closer to the surgical end effector of the surgical instrumentand further away from the surgeon. Moreover, to the extent that spatialterms such as “upper,” “lower,” “vertical,” “horizontal,” or the likeare used herein with reference to the drawings, it will be appreciatedthat such terms are used for exemplary description purposes only and arenot intended to be limiting or absolute. In that regard, it will beunderstood that surgical instruments such as those disclosed herein maybe used in a variety of orientations and positions not limited to thoseshown and described herein.

As used herein, the terms “about” and “approximately” for any numericalvalues or ranges indicate a suitable dimensional tolerance that allowsthe part or collection of components to function for its intendedpurpose as described herein.

I. Exemplary Surgical Stapling Instrument

FIGS. 1-2 show a motor-driven surgical instrument (10) suitable for usein a variety of surgical procedures. In the illustrated example,instrument (10) includes a handle assembly (12) and an interchangeableshaft assembly (14) releasably coupled to and extending distally fromhandle assembly (12). Interchangeable shaft assembly (14) includes asurgical end effector (16) arranged at a distal end thereof, and whichis configured to perform one or more surgical tasks or procedures. Insome applications, interchangeable shaft assembly (14) may beeffectively employed with a tool drive assembly of a roboticallycontrolled or automated surgical system. For example, interchangeableshaft assembly (14) may be employed with various robotic systems,instruments, components, and methods such as those disclosed in U.S.Pat. No. 9,072,535, entitled “Surgical Stapling Instruments WithRotatable Staple Deployment Arrangements,” issued Jul. 7, 2015, thedisclosure of which is incorporated by reference herein.

A. Handle Assembly of Surgical Stapling Instrument

Handle assembly (12) comprises a body (20) that includes a pistol grip(22) configured to be grasped by a clinician, and a closure trigger (24)configured to pivot toward and away from pistol grip (22) to selectivelyclose and open end effector (16), as described in greater detail below.In the present example, end effector (16) is configured to cut andstaple tissue captured by end effector (16). In other examples, endeffector (16) may be configured to treat tissue via application ofvarious other types of movements and energies, such as radio frequency(RF) energy and/or ultrasonic energy, for example.

As seen in FIGS. 2-4, handle assembly body (20) houses a supportstructure in the form of a handle frame (26) that supports a pluralityof drive systems configured to generate and apply various controlmotions to corresponding portions of interchangeable shaft assembly(14). In particular, handle frame (26) supports a first drive system inthe form of a closure drive system (30) that is operable to selectivelyclose and open end effector (16) to thereby capture and release tissue.Closure drive system (30) includes an actuator in the form of closuretrigger (24), which is pivotally supported by handle frame (26) and isoperatively coupled with end effector (16) via components of shaftassembly (14) described below. Closure trigger (24) is configured to besqueezed by a clinician toward pistol grip (22) from an unactuatedposition (FIG. 3A) that provides end effector (16) in an open state forreleasing tissue, to an actuated position (FIG. 3B) that provides endeffector (16) in a closed state for clamping tissue. Closure trigger(24) may be biased toward the unactuated position by a resilient member(not shown). As seen best in FIG. 4, closure drive system (30) furthercomprises a linkage assembly that couples closure trigger (24) with endeffector (16). The linkage assembly includes a closure link (32) and atransversely extending attachment pin (34) coupled to a distal end ofclosure link (32). Attachment pin (34) and the distal end of closurelink (32) are accessible through a distal opening in handle assembly(12).

Handle assembly body (20) further supports a second drive system in theform of a firing drive system (40) configured to apply firing motions tocorresponding portions of interchangeable shaft assembly (14) and itsend effector (16). In the present example, firing drive system (40)employs an electric motor (42) that is housed within pistol grip (22) ofhandle assembly (12) and is operatively coupled with end effector (16),as described below. Electric motor (42) may be of any suitable type,such as a DC brushed motor, a brushless motor, a cordless motor, asynchronous motor, a stepper motor, or any other suitable type ofelectric motor. Electric motor (42) is powered by a power source shownin the form of a power pack (44) removably coupled to a proximal portionof handle assembly body (20). Power pack (44) includes one or morebatteries (not shown) of any suitable type, and may be rechargeable orreplaceable.

As seen in FIG. 4, electric motor (42) is electrically coupled to andcontrolled by a circuit board (46) supported by handle frame (26) withinhandle assembly body (20). Circuit board (46) may include amicrocontroller and is configured to direct power from power pack (44)to electric motor (42) and thereby energize motor (42) to fire endeffector (16). Electric motor (42) is configured to interface with adrive gear arrangement (not shown) that is operable to actuate anelongate drive member (48) axially relative to handle frame (26) inresponse to activation of motor (42). As seen best in FIG. 5, a distalend of drive member (48) is exposed through a distal opening of handleassembly (12) and is configured to couple to a translating member ofshaft assembly (14) to thereby operatively couple motor (42) with endeffector (16), as described below.

Electric motor (42) is energized by battery pack (44) in response toactuation of a firing trigger (50), which is pivotally supported byhandle assembly (12) as best seen in FIGS. 3A and 3B. In the presentexample, firing trigger (50) is positioned “outboard” of closure trigger(24). Similar to closure trigger (24), firing trigger (50) is configuredto be squeezed by the clinician toward pistol grip (22) from anunactuated position (FIG. 3B) to an actuated position (not shown).Firing trigger (50) may be biased toward the unactuated position by aresilient member (not shown). When firing trigger (50) is depressed fromthe unactuated position to the actuated position, firing trigger (50)causes battery pack (44) to energize motor (42) to actuate drive member(48) longitudinally and thereby fire end effector (16). As shown inFIGS. 3A and 3B, handle assembly (12) further includes a firing triggersafety button (52) that is selectively pivotable between a safetyposition and a firing position to prevent inadvertent actuation offiring trigger (50).

As shown best in FIG. 5, elongate drive member (48) of firing drivesystem (40) includes a rack of teeth (54) formed on at least a proximalportion thereof for meshing engagement with a corresponding drive geararrangement (not shown) that interfaces with electric motor (42). Drivemember (48) further includes an attachment cradle (56) on a distal endthereof, which is configured to receive and couple with an elongatetranslating member of shaft assembly (14), described below. Drive member(48) is configured to configured to be driven by motor (42) from aproximal position to a distal position to thereby actuate thetranslating member of shaft assembly (14) and fire end effector (16).

B. Interchangeable Shaft Assembly of Surgical Stapling Instrument

As shown in FIGS. 1-2, interchangeable shaft assembly (14) of thepresent example includes a proximal nozzle (60), an elongate proximalclosure tube (62) extending distally from nozzle (60), an articulationjoint (64) disposed at a distal end of the closure tube (62), a distalclosure tube segment (66) coupled to a distal end of articulation joint(64), and end effector (16) extending distally therefrom.

End effector (16) includes a first jaw comprising an elongate channel(70) that receives a cartridge (72), and a second jaw comprising ananvil (74) configured to pivot relative to channel (70) between open andclosed positions for clamping tissue between anvil (74) and cartridge(72). Cartridge (72) is shown in the form of a conventional staplecartridge having features described in greater detail below, and isconfigured to fire a plurality of staples into tissue clamped by endeffector (16). In other examples, end effector (16) may be suitablyconfigured to apply a variety of other types of motions and energies totissue captured by end effector (16), such as radio frequency (RF)energy and/or ultrasonic energy, for example. For instance, cartridge(72) may be configured to apply RF to tissue as generally disclosed inU.S. Ser. No. 15/636,096, entitled “Surgical System Couplable WithStaple Cartridge And Radio Frequency Cartridge, And Method Of UsingSame,” filed Jun. 28, 2017, published as U.S. Pub. No. 2019/0000478 onJan. 3, 2019, issued as U.S. Pat. No. 11,298,128 on Apr. 12, 2022, thedisclosure of which is incorporated by reference herein.

Anvil (74) of end effector (16) is operatively coupled with closuredrive system (30) of handle assembly (12), and is configured to pivotbetween open and closed positions, about a pivot axis that extendstransversely to shaft axis (SA), in response to actuation of closuretrigger (24). In particular, anvil (74) is configured to as assume anopen position when closure trigger (24) is in the unactuated position,and a closed position when closure trigger (24) depressed to theactuated position. Anvil (74) is coupled with closure drive system (30)via proximal closure tube (62) and distal closure tube segment (66),among other components described below. Proximal closure tube (62) anddistal closure tube segment (66) are configured to translate proximallyand distally relative to nozzle (60) to thereby actuate anvil (74) aboutits pivot axis in response to actuation of closure trigger (24).

Articulation joint (64) is configured to provide articulation of endeffector (16) relative to proximal closure tube (62) and correspondingcomponents of shaft assembly (14) about an articulation axis (AA) thatextends transversely to shaft axis (SA). In some examples, end effector(16) may be articulated to a desired orientation by pushing end effector(16) against soft tissue and/or bone within the patient. In otherexamples, end effector (16) may be articulated by an articulation driver(not shown).

As best seen in FIG. 4, nozzle (60) of interchangeable shaft assembly(14) houses a support structure in the form of a tool chassis (80) thatrotatably supports nozzle (60). Nozzle (60) and end effector (16) areconfigured to rotate relative to tool chassis (80) about shaft axis(SA), as indicated in FIG. 1. As shown in FIG. 5, proximal closure tube(62) houses an internal spine (82) that is rotatably supported by toolchassis (80) (omitted from view in FIG. 5) at a proximal end and iscoupled to end effector (16) at a distal end. Tool chassis (80) furthersupports a closure shuttle (84) that is configured to translateproximally and distally relative to tool chassis (80). A distal end ofclosure shuttle (84) is coupled to and rotatably supports a proximal endof proximal closure tube (62). A proximal end of closure shuttle (84)includes a pair of proximally extending hooks (86) configured to couplewith closure drive system (30) of handle assembly (12). In particular,hooks (86) are configured to releasably capture attachment pin (34) ofclosure drive system (30) when interchangeable shaft assembly (14) iscoupled with handle assembly (12). Accordingly, actuation of closuretrigger (24) to the actuated position (see FIG. 3B) drives closureshuttle (84) distally, which in turn drives proximal closure tube (62)and distal closure tube segment (66) distally, thereby actuating anvil(74) to a closed position for clamping tissue with end effector (16).Returning trigger to the unactuated position (see FIG. 3A) actuatesthese components proximally, thereby returning anvil (74) to an openposition.

As seen best in FIG. 5, interchangeable shaft assembly (14) furtherincludes an internal firing system (90) configured to operatively couplewith firing drive system (40) of handle assembly (12) when shaftassembly (14) is coupled to handle assembly (12). Firing system (90)includes an intermediate firing shaft (92) slidably received withinspine (82) and proximal closure tube (62). Intermediate firing shaft(92) includes a proximal end having an attachment lug (94) configured torotatably seat within attachment cradle (56) of drive member (48) offiring drive system (40), and a distal end configured to couple to anelongate knife bar (96). Knife bar (96) is connected at its distal endto a knife member (98), which includes a sharpened cutting edge (99)configured to sever tissue clamped by end effector (16) as knife memberadvances distally through staple cartridge (72). Accordingly, actuationof firing trigger (50) actuates drive member (48) distally, which inturn drives intermediate firing shaft (92), knife bar (96), and knifemember (98) distally to thereby cut tissue and simultaneously firestaple cartridge (72), as described below. Knife member (98) may includeone or more anvil engagement features configured to engage and maintainanvil (74) in a closed state throughout cutting and stapling of tissue.

As seen best in FIG. 6, staple cartridge (72) includes a moldedcartridge body (100) that houses a plurality of staples (102) withinstaple cavities (104) that open upwardly through a staple deck (106) ofcartridge body (100). A plurality of staple drivers (108) are positionedwithin staple cavities (104), beneath staples (102). A cartridge tray(110) covers an open bottom side of cartridge body (100) and holdstogether the various components of staple cartridge (72). A wedge sled(112) is slidably received within slots formed in cartridge body (100),and is driven distally by knife member (98) upon actuation of firingdrive system (40). As wedge sled (112) advances distally through staplecartridge (72), wedge sled (112) cams staple drivers (108) upwardly tothereby drive staples (102) through tissue clamped by anvil (74) andinto staple forming pockets (not shown) formed in anvil (74), therebydeforming staples (102). Simultaneously, cutting edge (99) of knifemember (98) severs the tissue clamped in end effector (16). After firingstaple cartridge (72), knife member (98) may be retracted to a proximalposition to thereby permit opening of anvil (74) and release of thestapled/severed tissue.

C. Electrical Connections Within Surgical Instrument

Interchangeable shaft assembly (14) and variations thereof that aresuitable for use with handle assembly (12) may employ one or moresensors and/or various other electrical components that requireelectrical communication with handle circuit board (46) of handleassembly (12). For instance, a proximal portion of shaft assembly (14)and/or end effector (16) may include one or more sensors (see e.g., FIG.8) and/or one or more RF electrodes (not shown) configured toelectrically couple with handle circuit board (46) to enable operationthereof. As described below, shaft assembly (14) is suitably configuredto enable rotation of end effector (16), among other components of shaftassembly (14), relative to handle assembly (12) while maintainingelectrical coupling between shaft assembly (14) and handle assembly(12).

As shown in FIG. 7, interchangeable shaft assembly (14) includes a slipring assembly (120) housed within nozzle (60). Slip ring assembly (120)is configured to electrically couple shaft assembly (14) with handleassembly (12) for communication of electrical power and/or sensorsignals between end effector (16) and handle circuit board (46). Slipring assembly (120) is configured to provide such electricalcommunication while facilitating rotation of nozzle (60) and endeffector (16), among other rotating components of shaft assembly (14),relative to tool chassis (80) and handle assembly (12) about shaft axis(SA). Slip ring assembly (120) comprises a proximal connector flange(122) mounted to a chassis flange (126) that extends distally from toolchassis (80), and a distal connector flange (124) secured to an interiorof nozzle (60). Distal connector flange (124) is configured to rotatewith nozzle (60) relative to tool chassis (80) and chassis flange (126).Accordingly, the proximal face of distal connector flange (124)confronts and is configured to rotate relative to a distal face ofproximal connector flange (122), about shaft axis (SA).

The distal face of proximal connector flange (122) of slip ring assembly(120) includes a plurality of annular conductors (128) arrangedsubstantially concentrically. The proximal face of distal connectorflange (124) supports one or more electrical coupling members (130) eachsupporting a plurality of electrical contacts (not shown). Eachelectrical contact is positioned to contact a respective annularconductor (128) of proximal connector flange (122). Such an arrangementpermits relative rotation between proximal connector flange (122) anddistal connector flange (124) while maintaining electrical contacttherebetween. Proximal connector flange (122) includes an electricalconnector (132) extending proximally from a proximal face of proximalconnector flange (122). Electrical connector (132) is configured toelectrically couple annular conductors (128) with a shaft circuit board(134), shown schematically in FIG. 4, which may be mounted to shaftchassis (80) and include a microcontroller.

D. Attachment of Interchangeable Shaft Assembly to Handle Assembly

As described in greater detail below, interchangeable shaft assembly(14) is configured to be releasably coupled with handle assembly (12).It will be appreciated that various other types of interchangeable shaftassemblies having end effectors configured for various types of surgicalprocedures may be used in combination with handle assembly (12)described above.

As shown best in FIG. 4, a proximal end of tool chassis (80) ofinterchangeable shaft assembly (14) includes a pair of taperedattachment members (150) extending transversely to shaft axis (SA), anda shaft-side electrical connector (152) positioned therebetween. Shaftelectrical connector (152) is in electrical communication with shaftcircuit board (134) of shaft assembly (14). A distal end of handle frame(26) of handle assembly (12) includes a pair of dovetail receiving slots(154), and a handle-side electrical connector (156) arrangedtherebetween. Handle electrical connector (156) is in electricalcommunication with handle circuit board (46) of handle assembly (12).During attachment of shaft assembly (14) to handle assembly (12), asdescribed below, tapered attachment members (150) are received withindovetail receiving slots (154) along an installation axis (IA) that istransverse to shaft axis (SA). Additionally, shaft electrical connector(152) is electrically coupled with handle electrical connector (156).The proximal end of interchangeable shaft assembly (14) additionallyincludes a latch assembly (158) configured to releasably latch toolchassis (80) to handle frame (26) of handle assembly (12) when shaftassembly (14) is coupled with handle assembly (12).

As shown in FIG. 4, to attach interchangeable shaft assembly (14) tohandle assembly (12), the clinician first aligns tapered attachmentmembers (150) of tool chassis (80) with dovetail receiving slots (154)of handle frame (26). The clinician then moves shaft assembly (14)toward handle assembly (12) along installation axis (IA), therebyseating tapered attachment members (150) within dovetail receiving slots(154) and lockingly engaging latch assembly (158) with a distal portionof handle assembly (12). In doing so, attachment lug (94) ofintermediate firing shaft (92) is also seated within cradle (56) oflongitudinally movable drive member (48), thereby operatively couplingfiring system (90) of shaft assembly (14) with firing drive system (40)of handle assembly (12). Additionally, proximal hooks (86) of closureshuttle (84) slide over and capture opposed lateral ends of attachmentpin (34) extending from closure link (32), thereby operatively couplingthe anvil closure components of shaft assembly (14) with closure drivesystem (30) of handle assembly (12). Additionally, during attachment ofshaft assembly (14) with handle assembly (12), shaft electricalconnector (152) on tool chassis (80) is electrically coupled with handleelectrical connector (156) on handle frame (26), thereby placing shaftcircuit board (134) of shaft assembly (14) in electrical communicationwith handle circuit board (46) of handle assembly (12).

In various examples, surgical instrument (10) may be further configuredin accordance with one or more teachings of U.S. Pat. No. 9,345,481,entitled “Staple Cartridge Tissue Thickness Sensor System,” issued May24, 2016; U.S. Pat. No. 8,608,045, entitled “Powered Surgical Cuttingand Stapling Apparatus With Manually Retractable Firing System,” issuedDec. 17, 2013; U.S. Ser. No. 15/635,663, entitled “Method ForArticulating A Surgical Instrument,” filed Jun. 28, 2017, published asU.S. Pub. No. 2019/0000465 on Jan. 3, 2019, issued as U.S. Pat. No.10,765,427 on Sep. 8, 2020; U.S. Ser. No. 15/635,631, entitled “SurgicalInstrument With Axially Movable Closure Member,” filed Jun. 28, 2017,published as U.S. Pub. No. 2019/0000464 on Jan. 3, 2019, issued as U.S.Pat. No. 10,639,037 on May 5, 2022; U.S. Ser. No. 15/635,837, entitled“Surgical Instrument Comprising An Articulation System Lockable To AFrame,” filed Jun. 28, 2017, published as U.S. Pub. No. 2019/0000472 onJan. 3, 2019, issued as U.S. Pat. No. 11,246,592 on Feb. 15, 2022; U.S.Pat. Pub. No. 2016/0066911, entitled “Smart Cartridge Wake Up OperationAnd Data Retention,” published Mar. 10, 2016, issued as U.S. Pat. No.10,135,242 on Nov. 20, 2018; U.S. Pat. Pub. No. 2015/0272575, entitled“Surgical Instrument Comprising A Sensor System,” published Oct. 1,2015, issued as U.S. Pat. No. 9,913,642 on Mar. 13, 2018; U.S. Pat. Pub.No. 2014/0263552, entitled “Staple Cartridge Tissue Thickness SensorSystem,” published Sep. 18, 2014 now abandoned; and/or U.S. Pat. Pub.No. 2014/0263541, entitled “Articulatable Surgical Instrument ComprisingAn Articulation Lock,” published Sep. 18, 2014, now abandoned, thedisclosures of which are incorporated by reference herein.

E. Exemplary End Effector With Sensors

In some instances, it may be desirable to provide the end effector of asurgical instrument with one or more sensors for sensing variousoperating conditions of the end effector. Such sensed conditions canthen be communicated as electrical signals to a controller of thesurgical instrument, such as a controller of shaft circuit board (134)and/or handle circuit board (46) of instrument (10) described above. Thecontroller(s) may then take one or more actions in response to receivingsuch signals, such as providing one or more indications to the clinicianoperating the instrument.

FIG. 8 illustrates an exemplary alternative end effector (160) suitablefor use with surgical instrument (10) described above. End effector(160) is similar to end effector (16) described above in that endeffector (160) includes a first jaw comprising an elongate channel (162)that receives a staple cartridge (164), and a second jaw comprising ananvil (166) configured to pivot relative to channel (162) between openand closed positions for clamping tissue (168) between anvil (166) andstaple cartridge (164). Staple cartridge (164) may be similar to staplecartridge (72) described above.

End effector (160) differs from end effector (16) in that end effector(160) includes a first sensor (170) disposed on a tissue clamping sideof anvil (166), and a plurality of second sensors (172) spaced along alength of channel (162). In other versions, one or more sensors, such asone or more of second sensors (172), may be provided on staple cartridge(164). In the present example, first sensor (170) is configured todetect one or more conditions of end effector (160), such as a gap (G)between anvil (166) and staple cartridge (164), which may correspond toa thickness of tissue (168) clamped by end effector (160). Secondsensors (172) are also configured to detect one or more conditions ofend effector (160) and/or of tissue (168) clamped by end effector (160).For instance, second sensors (172) may be configured to detect one ormore conditions such as a color of staple cartridge (164), a length ofstaple cartridge (164), a clamping condition of end effector (160),and/or the number of actual and/or remaining uses of end effector (160)and/or staple cartridge (164), for example. While end effector (160) isshown having one first sensor (160) and four second sensors (172),various other suitable quantities and arrangements of sensors (170, 172)may be provided in other examples.

Each sensor (170, 172) may comprise any sensor type suitable formeasuring the respective one or more conditions of end effector (160).For instance, each sensor (170, 172) may comprise a magnetic sensor(e.g., a Hall effect sensor), a strain gauge, a pressure sensor, aninductive sensor (e.g., an eddy current sensor), a resistive sensor, acapacitive sensor, or an optical sensor, for example. Each sensor (170,172) is configured to communicate electrical signals corresponding to asensed condition of end effector (160) to shaft circuit board (134),which may in turn communicate information based on the signals to handlecircuit board (46), via slip ring assembly (120) described above.

It should be understood that channel (162) may selectively receivestaple cartridge (164) such that staple cartridge (164) may be attachedto channel (162), used in accordance with the description herein,removed from channel (162), and replaced with an unused, second staplecartridge (164). Therefore, in versions in which second sensors (172)are provided on staple cartridge (164), second sensors (172) may beconfigured to selectively establish an electrical connection with shaftcircuit board (134) once staple cartridge (164) is suitably coupled tochannel (162). In the current example, second sensors (172) each includean electrical contact (174), while channel (162) includes a plurality ofelectrical contacts (180). Corresponding contacts (174, 180) aredimensioned to electrically couple with each other when staple cartridge(164) is suitably coupled with channel (162). Additionally, channel(162) includes electrical traces (182) extending from contacts (180) allthe way to electrical coupling member (130) of slip ring assembly (120).Therefore, when staple cartridge (164) is suitably coupled with channel(162), second sensors (172) are in electrical communication with shaftcircuit board (134).

II. Exemplary Slip Ring Assembly with Axially Spaced Electrical Contacts

During use of surgical instrument (10) in surgical procedures, certainelectrical components of instrument (10) may be vulnerable to fluidingress, which can undesirably cause shorting of correspondingelectrical pathways in instrument (10). For instance, a conductive fluidbridge could form between two or more of annular electrical contacts(128) of slip ring assembly (120), allowing an electrical short circuitto occur through the fluid bridge. Such electrical short circuitingcould result in the failure of one or more electrical systems ofsurgical instrument (10). The exemplary slip ring assembly (200)described below includes various features that are configured to preventelectrical shorting between its electrical contacts in the presence offluid. Similar to slip ring assembly (120) described above, slip ringassembly (200) is configured to enable electrical communication betweenshaft assembly (14) and handle assembly (12) while permitting relativerotation therebetween.

As shown in FIGS. 9-11, slip ring assembly (200) of the present exampleextends distally from chassis flange (126) of tool chassis (80) and ishoused within nozzle (60). Slip ring assembly (200) includes an outercontact support structure in the form of a contact sleeve (202) thatencircles a proximal portion of closure tube (62) and supports anaxially-spaced arrangement of outer electrical contacts in the form ofring contacts (204). Slip ring assembly (200) further includes an innercontact support structure in the form of a contact block (206) that iscoupled to the proximal portion of closure tube (62) and supports anaxially-spaced arrangement of inner electrical contacts in the form ofbrush contacts (208). Each brush contact (208) is configured toelectrically couple with a respective ring contact (204). As describedin greater detail below, contact sleeve (202) and rings contacts (204)are configured to remain axially and rotationally fixed relative to toolchassis (80), while contact block (206) and brush contacts (208) areconfigured to rotate with closure tube (62) about shaft axis (SA)relative to contact sleeve (202) and other stationary components ofsurgical instrument (10). In other versions of slip ring assembly (200),a reverse configuration may be provided in which ring contacts (204) aresupported by closure tube (62) and brush contacts (208) are supported bya stationary contact support structure positioned radially outward ofclosure tube (62), such that ring contacts (204) are configured torotate relative to brush contacts (208).

As shown best in FIG. 10, contact sleeve (202) includes a cylindricalbody (210) that encircles closure tube (62) coaxially, and a proximalflange (212) that confronts distal chassis flange (126) of tool chassis(80). Each ring contact (204) is recessed within a respective groove(214) formed in a radially inner surface of cylindrical body (210), suchthat ring contacts (204) face inwardly toward and are spaced radiallyoutwardly from an outer surface of closure tube (62). Ring contacts(204) may be formed through stamping, rolling, and welding of sheetmaterial, or through laser-cutting of tube stock material, for example.Contact sleeve (202) may be formed of an electrically insulativematerial, such as plastic, that electrically insulates ring contacts(204) from one another. As described in greater detail below, each ringcontact (204) is spaced axially from the one or more immediatelyadjacent ring contacts (204), and each respective brush contact (208) islikewise spaced axially from the one of more immediately adjacent brushcontacts (208), by an axial distance suitable to provide a minimumimpedance that prevents electrical shorting between axially adjacentcontacts (204, 208) in the presence of fluid.

Proximal flange (212) of contact sleeve (202) includes an electricalconnector (216) that is configured to couple with a distal electricalconnector portion (218) of shaft circuit board (134), which projectsdistally through an opening (220) formed in chassis flange (126).Electrical connector (216) is electrically coupled with ring contacts(204) via outer leads (222). Electrical connectors (216, 218) areconfigured to releasably couple together, for example via snap-fitengagement, to define an in-line slip connection that enables selectiveassembly and disassembly of slip ring assembly (200) along shaft axis(SA), for example for cleaning purposes. Electrical connectors (216,218) thus cooperate to electrically couple slip ring assembly (200) withshaft circuit board (134). Shaft circuit board (134), in turn, iselectrically coupled with the electrical components of handle assembly(12), including handle circuit board (46), via engagement of shaftelectrical connector (152) with handle electrical connector (156) in themanner described above. It will be understood that shaft and handleelectrical connectors (152, 156) may be substituted with alternativeelectrical connectors of the exemplary types disclosed in the referencesincorporated by reference herein.

As shown in FIGS. 10-12, contact block (206) of the present example hasa generally rectangular body and is exposed through a longitudinallyextending opening (224) formed in the upper side of the proximal portionof closure tube (62). Similar to contact sleeve (202), contact block(206) may be formed of an electrically insulating material thatelectrically insulates brush contacts (208) from one another. Contactblock (206) is supported by closure tube (62) such that contact block(206) is configured to rotate with closure tube (62) about shaft axis(SA). In the present example, contact block (206) is also longitudinallyslidable relative to closure tube (62). This enables closure tube (62)to translate proximally and distally relative to contact block (206), tothereby actuate anvil (74) of end effector (16) between open and closedpositions in the manner described above, while contact block (206)remains axially fixed relative to contact sleeve (202). Thisconfiguration, enabled by a suitable length of longitudinal opening(224), allows brush contacts (208) to remain axially aligned with, andthereby electrically coupled to, the respective ring contacts (204) evenduring actuation of closure tube (62). In other examples, contact block(206) may be fixed axially to closure tube (62) and thus configured totranslate with closure tube (62) relative to tool chassis (80). In suchexamples, contact sleeve (202) may be configured to translate axiallywith closure tube (62) and contact block (206) relative to tool chassis(80), to maintain axial alignment of joined electrical contacts (204,208), while remaining rotationally fixed relative to tool chassis (80).

As shown best in FIG. 12, brush contacts (208) of the present exampleare in the form of arched spring contacts that project radiallyoutwardly from contact block (206). As shown in FIG. 10, brush contacts(208) are electrically coupled with one or more sensors or otherelectrical devices, such as electrodes, supported by shaft assembly (14)via inner leads (226) that extend through contact block (206). As shownin FIGS. 12-13B, each brush contact (208) includes chamfered proximaland distal edges configured to facilitate sliding engagement of contactsleeve (202) over brush contacts (208) during assembly of contact sleeve(202) with shaft assembly (14), or during subsequent disassembly.Contact sleeve (202) may be slid proximally over closure tube (62) andbrush contacts (208), as shown in FIGS. 13A-13B, until sleeve electricalconnector (216) engages distal electrical connector portion (218) ofshaft circuit board (134), as shown in FIG. 10.

As shown best in FIGS. 10 and 11, slip ring assembly (200) furtherincludes a layer (228) of electrically insulative material thatencircles the outer surface of the proximal portion of closure tube (62)that supports contact block (206). In the present example, insulativelayer (228) extends longitudinally such that a proximal end of layer(228) is positioned proximally of a proximal end of opening (224) and aproximal-most ring contact (204), and a distal end of layer ispositioned distally of a distal end of opening (224) and a distal-mostring contact (204). Insulative layer (228) is configured to preventelectrical shorting of electrical contacts (204, 208) through closuretube (62) in the presence of fluid in slip ring assembly (200). In someversions, insulative layer (228) may extend longitudinally along closuretube (62) for lengths greater than the exemplary length shown anddescribed herein.

As shown best in FIGS. 12 and 14, ring contacts (204) of contact sleeve(202) include a pair of high-power (or “high-energy”) ring contacts (204a), and a pair of low-power (or “low-energy”) ring contacts (204 b).Similarly, brush contacts (208) include a corresponding pair ofhigh-power brush contacts (208 a) that couple with high-power ringcontacts (204 a), and a pair of low-power brush contacts (208 b) thatcouple with low-power ring contacts (204 b). High-power contacts (204 a,208 a) correspond to electrical pathways configured to transmitcomparatively higher levels of electrical energy, such as RF energysuitable to treat tissue in an electrosurgical procedure. Low-power ringcontacts (204 b) correspond to electrical pathways configured totransmit comparatively lower levels of electrical energy, such aselectrical signals generated by one or more sensors of shaft assembly(14). Accordingly, in the present example high-power contacts (204 a,208 a) are formed with a greater axial width than low-power contacts(204 b, 208 b). In particular, as shown in FIG. 14, high-power ringcontacts (204 a) have a greater axial width (W1), and low-power ringcontacts (204 b) have a smaller axial width (W2).

In one example, a first coupled pair of high-power contacts (204 a, 208a) correspond to a high-power active path, and the second coupled pairof high-power contacts (204 a, 208 a) correspond to a high-power returnpath. Similarly, a first coupled pair of low-power contacts (204 b, 208b) correspond to a low-power active path, and the second coupled pair oflow-power contacts (204 b, 208 b) correspond to a low-power return path.While the exemplary version of slip ring assembly (200) shown anddescribed herein includes four ring contacts (204) and four brushcontacts (208), various other suitable quantities of contacts (204, 208)may be provided in other versions to accommodate various quantities ofelectrical pathways.

As noted above, each ring contact (204) and each brush contact (208) isspaced axially from the other ring contacts (204) and the other brushcontacts (208), respectively, by an axial distance suitable to achieve aminimum impedance that prevents electrical shorting among ring contacts(204) and among brush contacts (208) in the presence of fluid. Inparticular, each high-power source contact (204 a, 208 a) is spacedaxially from the respective high-power return contact (204 a, 208 a) byan axial distance suitable to prevent electrical shorting therebetweenin the presence of fluid. Similarly, each low-power source contact (204b, 208 b) is spaced axially from the respective low-power return contact(204 b, 208 b) by an axial distance suitable to prevent electricalshorting therebetween in the presence of fluid. Additionally, eachindividual ring contact (204) is spaced axially from the one or moreimmediately adjacent ring contacts (204) by an axial distance suitableto prevent electrical shorting therebetween in the presence of fluid.Likewise, each individual brush contact (208) is spaced axially from theone or more immediately adjacent ring contacts (204) by an axialdistance suitable to prevent electrical shorting therebetween in thepresence of fluid.

FIG. 14 shows an exemplary arrangement of ring contacts (204) in whichhigh-power ring contacts (204 a) are disposed at proximal and distalpositions along the length of contact sleeve (202), and low-power ringcontacts (204 b) are disposed at medial positions between high-powercontacts (204 a). Brush contacts (208) of the present example arearranged in a similar manner on contact block (206). Each ring contact(204) is recessed within its respective groove (214) of contact sleeve(202) such that the exposed surface of ring contact (204) is disposed ata radial depth (D) from the radially inner surface of contact sleeve(202). High-power contacts (204 a) are spaced apart axially by a firstaxial distance (X1), and low-power contacts (204 b) are spaced apartaxially by a second axial distance (X2) that is less than first axialdistance (X1). Additionally, each low-power contact (204 b) is spacedaxially from the immediately adjacent high-power contact (204 a) by athird axial distance (X3), which may be greater than second axialdistance (X2) but less than first axial distance (X1), such that theaxial spacing between adjacent ring contacts (204) is non-uniform.Accordingly, axial distances (X1, X2, X3) of the present example arecharacterized as follows: X1>X3>X2. Additionally, first axial distance(X1) may be characterized as follows: X1=X2+2(X3)+2(W2). It will beappreciated that brush contacts (208) may be provided with axial widthsand axial spacings similar to those of ring contacts (204), such thatbrush contacts (208) properly align with respective ring contacts (204).

In one example, each high-power ring contact (204 a) may have an axialwidth (W1) of approximately 0.100 inches, and each low-power ringcontact (204 b) may have an axial width (W2) of approximately 0.050inches. Additionally, low-power ring contacts (204 b) may be spacedapart by a second axial distance (X2) of approximately 0.050 inches, andeach low-power ring contact (204 b) may be spaced axially from theimmediately adjacent high-power ring contact (204 a) by a third axialdistance (X3) of approximately 0.100 inches.

FIG. 15 shows an enlarged view of low-power ring contacts (204 b) ofcontact sleeve (202). As discussed above, each ring contact (204) of thepresent example is recessed within a respective groove (214) formed inthe radially inner surface of contact sleeve (202). Accordingly, eachring contact (204) is separated from each adjacent ring contact (204) byan annular rim (230) defined by contact sleeve body (210). Annular rim(230) functions as an electrically insulating barrier in the presence ofa fluid bridge (232) that may form between axially adjacent contacts(204, 208) during use. Axial distances (X2, X3) between adjacent ringcontacts (204) may be selected such that each electrically insulatingrim (230) promotes an electrical impedance within the respective fluidbridge (232) that is sufficient to prevent electrical shorting throughfluid bridge (232). Additionally, each rim (230) may have chamferedproximal and distal edges configured to engage brush contacts (208) tofacilitate sliding of contact sleeve (202) over brush contacts (208)during assembly and disassembly of slip ring assembly (200), asdescribed above in connection with FIGS. 12-13B.

FIG. 16 shows an exemplary alternative configuration in which theelectrically insulating effect of rim (230) between low-power ringcontacts (204 b) is enhanced by an electrically insulating element(234), secured to rim (230). Electrically insulating element (234),which may be in the form of an O-ring for example, projects radiallyfrom rim (230) in a direction toward closure tube (62), and isconfigured to increase the impedance in the respective fluid bridge(232). In some cases, inclusion of an electrically insulating element(234) between two ring contacts (204) may enable the corresponding axialspacing therebetween (X2, X3) (i.e., the axial width of the respectiverim (230)) to be reduced while still effectively preventing electricalshorts between the adjacent ring contacts (204) through fluid bridge(232). Accordingly, it will be understood in light the descriptionprovided above that axial spacings (X1, X2, X3) between contacts (204,208), electrical contact axial widths (W1, W2), ring contact recessdepth (D), and the presence of electrically insulating barriers betweenaxially adjacent contacts (204, 208) collectively affect the resultingimpedance of a fluid bridge (232) formed between adjacent contacts (204,208). Accordingly, any one or more of these factors may be suitablyadjusted as desired to achieve a certain minimum impedance sufficient toprevent electrical shorting in slip ring assembly (200) in the presenceof fluid. In some examples, electrical shorting of electrical contacts(204, 208) through fluid may be further averted by coating one of morecontacts (204, 208) with a conductive composite material, such as carbonink, silver-doped epoxy, or nickel-doped epoxy, for example.

III. Exemplary Electrical Connectors in End Effector

It may be desirable to provide a distal portion of shaft assembly (14)with an electrical connector to facilitate electrical coupling of one ormore sensors or other electrical elements of shaft assembly (14) with aslip ring assembly of surgical instrument (10), such as one of slip ringassemblies (120, 200). FIG. 17 shows an exemplary arrangement in which aproximal end of end effector channel (70) supports an electricalconnector (240), depicted schematically. Electrical connector (240) isconfigured to electrically couple sensors or other electrical elementsof shaft assembly (14) with the rotating electrical contacts of the slipring assembly of instrument (10). For instance, electrical connector(240) may be configured to electrically couple such sensors and/or otherelectrical elements with the electrical contacts of distal flange (124)of slip ring assembly (120), or with brush contacts (208) of slip ringassembly (200). As shown schematically in FIG. 17, electrical connector(240) accomplishes this by electrically coupling a first plurality ofconductive members (242) with a second plurality of conductive members(244), each of which may be in the form of wires. First conductivemembers (242) extend distally and electrically communicate with thesensors and/or other electrical elements of shaft assembly (14). Secondconductive members (244) extend proximally and electrically communicatewith the rotating electrical contacts of the slip ring assembly. FIGS.18-20C, described below, show various exemplary configurations ofelectrical connector (240).

FIG. 18 shows an electrical connector (250) that embodies a firstexemplary configuration of electrical connector (240). Electricalconnector (250) is in the form of a hinged zero-insertion-force (“ZIF”)connector having a base plate (252) and a locking lever (254) pivotablycoupled to base plate (252). A first set of wires (256) is electricallycoupled with base plate (252) and extends distally to electricallyconnect with the sensors or other electrical elements of end effector(16), for example via electrical traces (182) described above. A secondset of wires (258) is configured to be received proximally by electricalconnector (250) for electrical coupling with first wires (256). Lockinglever (254) is configured to pivot relative to base plate (252) betweenan open position in which connector (250) is configured to receivesecond wires (258), and a closed position in which locking lever (254)is configured to clamp second wires (258) against base plate (252) andthereby electrically couple first wires (256) with second wires (258).Electrical connector (250) may be oriented within end effector (16) suchthat base plate (252) is secured to channel (70), and such that lockinglever (254) is configured to pivot about an axis that extendstransversely to shaft axis (SA).

FIG. 19 shows another electrical connector (260) that embodies a secondexemplary configuration of electrical connector (240). Similar toelectrical connector (250), electrical connector (260) is in the form ofa hinged zero-insertion-force (“ZIF”) connector having a base plate(262) and a locking lever (264) pivotably coupled to base plate (262).Base plate (262) is configured to electrically couple with a first setof wires (not shown) coupled with sensors or other electrical elementsof end effector (16). Locking lever (264) is configured to pivot betweenopen and closed positions relative to base plate (262) to clamp a secondset of wires (265) against base plate (262), via a spike (266), andthereby electrically couple the first wires with second wires (265).Connector (260) of the present example is configured to lockingly engagechannel (70) of end effector (16), for example with a snap-fitengagement. Base plate (262) includes a lower arm (268) configured toproject downwardly through an opening formed in a base surface ofchannel (70), and hook the base surface against base plate (262).

FIGS. 20A-20C show another electrical connector (270) that embodies athird exemplary configuration of electrical connector (240). Electricalconnector (270) includes a lever (272) pivotably coupled to a basestructure (274) that is supported by end effector channel (70), orotherwise defined by channel (70). The underside of lever (272) includesa plurality of teeth (276) arranged along a length of lever (272), and afin (278) arranged at a free end of lever (272). Fin (278) is configuredto seat within a recess (280) formed in base structure (274) when lever(272) is pivoted from an open position (FIG. 20A) to a closed position(FIG. 20C). Recess (280) is at least partially filled with a multi-partepoxy (282).

As shown in FIG. 20A, with lever (272) in the open position, a firstwire (284) is inserted underneath lever (272) from a first direction,and a second wire (286) is inserted underneath lever (272) from anopposed second direction, such that exposed ends of wires (284, 286)overlap one another. As shown in FIG. 20B, lever (272) is pivoteddownwardly toward base structure (274) so that fin (278) is receivedwithin recess (280) and causes the multiple parts of epoxy (282) to mixtogether and begin curing. As shown in FIG. 20C, as fin (278) fullyseats within recess (280), fin (278) causes mixed epoxy (282) to travelupwardly from recess (280) and encapsulate the overlapping wires (284,286). Upon curing, epoxy (282) bonds wires (284, 286) together andthereby establishes a permanent electrical connection. Lever (272) maybe held in its fully closed position while epoxy (282) cures by anysuitable locking mechanism, such as a snap feature for example.

Multi-part, mixable epoxy may also be used in connection with either ofconnectors (250, 260) described above, as well as various otherconfigurations of electrical connector (240). For instance, connector(250, 260) may include an epoxy capsule that is configured to beruptured by locking lever (254, 264) when lever (254, 264) is pivotedfrom its open position to its closed position. Epoxy would then curewhile lever (254, 264) remains in its closed position, therebystrengthening the electrical connector established by connector (260).In other examples, any configuration of electrical connector (240),including those described above, may be coated with a suitablethermoplastic, such as TECHNOMELT®, in whole or in part to preventunintended disengagement of wires from electrical connector (240) afterassembly.

IV. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

A surgical instrument, comprising: (a) a body assembly; (b) a shaftassembly extending distally from the body assembly along a shaft axis,wherein the shaft assembly includes an outer tube configured to rotaterelative to the body assembly about the shaft axis; (c) an end effectorat a distal end of the shaft assembly, wherein the end effector isoperable to treat tissue; and (d) a slip ring assembly configured toenable electrical communication between the shaft assembly and the bodyassembly while permitting relative rotation therebetween, wherein theslip ring assembly comprises: (i) a first electrical contact supportedby the outer tube, and (ii) a second electrical contact positionedradially outward of the outer tube, wherein the first and secondelectrical contacts are electrically coupled together, wherein the firstelectrical contact is configured to rotate with the outer tube about theshaft axis relative to the second electrical contact while the first andsecond electrical contacts remain electrically coupled.

Example 2

The surgical instrument of Example 1, wherein the slip ring assembly isdisposed at a proximal end of the shaft assembly.

Example 3

The surgical instrument of any of the preceding Examples, wherein theshaft assembly further comprises a nozzle, wherein the slip ringassembly is housed within the nozzle.

Example 4

The surgical instrument of any of the preceding Examples, wherein theslip ring assembly further comprises a contact support structure thatsupports the second electrical contact, wherein the contact supportstructure is rotationally fixed relative to the body assembly.

Example 5

The surgical instrument of Example 4, wherein the shaft assemblyincludes a chassis that rotatably supports the outer tube, wherein thecontact support structure is coupled to the chassis.

Example 6

The surgical instrument of Example 5, wherein the contact supportstructure extends distally from the chassis.

Example 7

The surgical instrument of any of Examples 4 through 6, wherein thecontact support structure comprises a sleeve, wherein the sleeveencircles the outer tube and the first electrical contact.

Example 8

The surgical instrument of any of the preceding Examples, wherein one ofthe first electrical contact or the second electrical contact comprisesa ring contact, wherein the other of the first electrical contact or thesecond electrical contact comprises a brush contact.

Example 9

The surgical instrument of Example 8, wherein the brush contact includesan angled distal edge, wherein the angled distal edge is configured topromote sliding engagement of the first contact with the second contactin a direction parallel to the shaft axis.

Example 10

The surgical instrument of any of the preceding Examples, wherein theslip ring assembly includes a plurality of first electrical contactsspaced axially and supported by the outer tube, and a plurality ofsecond electrical contacts spaced axially and positioned radiallyoutward of the first electrical contacts, wherein the first electricalcontacts are configured to rotate with the outer tube relative to thesecond electrical contacts while remaining electrically coupled with thesecond electrical contacts.

Example 11

The surgical instrument of Example 10, wherein the first electricalcontacts are spaced apart with non-uniform axial spacing, wherein thesecond electrical contacts are spaced apart with non-uniform axialspacing.

Example 12

The surgical instrument of Example 10, wherein the slip ring assemblyfurther comprises a contact support structure that supports the secondelectrical contacts, wherein each adjacent pair of the second electricalcontacts is separated by an electrically insulating barrier.

Example 13

The surgical instrument of Example 12, wherein the electricallyinsulating barrier is defined by the contact support structure.

Example 14

The surgical instrument of any of Examples 12 through 13, wherein theelectrically insulating barrier comprises an electrically insulatingelement coupled to the contact support structure.

Example 15

The surgical instrument of any of the preceding Examples, wherein theshaft assembly is configured to releasably attach to the body assembly,wherein the body assembly includes a first electrical connector, whereinthe shaft assembly includes a second electrical connector configured toelectrically couple with the first electrical connector when the shaftassembly is attached to the body assembly.

Example 16

A surgical instrument, comprising: (a) a body assembly; (b) a shaftassembly extending distally from the body assembly along a shaft axis,wherein the shaft assembly includes an outer tube configured to rotaterelative to the body assembly about the shaft axis; (c) an end effectorat a distal end of the shaft assembly, wherein the end effector isoperable to treat tissue; and (d) a slip ring assembly configured toenable electrical communication between the shaft assembly and the bodyassembly while permitting relative rotation therebetween, wherein theslip ring assembly comprises: (i) a plurality of brush contacts spacedaxially along the shaft axis, and (ii) a plurality of ring contactsspaced axially along the shaft axis, wherein the ring contacts encircleand electrically couple with the brush contacts, wherein one of thebrush contacts or the ring contacts are configured to rotate with theouter tube about the shaft axis relative to the other of the brushcontacts or the ring contacts while the brush contacts and the ringcontacts remain electrically coupled.

Example 17

The surgical instrument of Example 16, wherein the brush contacts andthe ring contacts are configured to electrically engage at a locationradially outward of the outer tube.

Example 18

The surgical instrument of any of Examples 16 through 17, wherein thebrush contacts are supported by the outer tube, wherein the ringcontacts are supported by a sleeve that encircles the outer tube.

Example 19

A surgical instrument, comprising: (a) a body assembly; (b) a shaftassembly extending distally from the body assembly along a shaft axis,wherein the shaft assembly includes an outer tube configured to rotaterelative to the body assembly about the shaft axis; (c) an end effectorat a distal end of the shaft assembly, wherein the end effector isoperable to treat tissue; and (d) a slip ring assembly configured toenable electrical communication between the shaft assembly and the bodyassembly while permitting relative rotation therebetween, wherein theslip ring assembly comprises: (i) a plurality of brush contacts arrangedaxially, wherein the brush contacts are spaced apart with non-uniformaxial spacing, and (ii) a plurality of ring contacts arranged axiallyand configured to electrically couple with the brush contacts, whereinthe ring contacts are spaced apart with non-uniform axial spacing,wherein the non-uniform axial spacing of the contacts is configured toestablish impedances that prevent electrical shorting betweennon-coupled pairs of the contacts in the presence of fluid, wherein oneof the brush contacts or the ring contacts are configured to rotate withthe outer tube about the shaft axis relative to the other of the brushcontacts or the ring contacts while the brush contacts and the ringcontacts remain electrically coupled.

Example 20

The surgical instrument of Example 19, wherein the ring contacts includea pair of high-power ring contacts each having a first axial width and apair of low-power ring contacts each having a second axial width smallerthan the first axial width, wherein the high-power ring contacts arespaced apart by a first axial distance and the low-power ring contactsare spaced apart by a second axial distance smaller than the first axialdistance.

V. Miscellaneous

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

Further, any one or more of the teachings, expressions, embodiments,examples, etc. described herein may be combined with any one or more ofthe teachings, expressions, embodiments, examples, etc. described inU.S. application Ser. No. 15/934,139, entitled “Surgical Instrument WithCompressible Electrical Connector,” filed on Mar. 23, 2018, published asU.S. Pub. No. 2019/0290307 on Sep. 26, 2019, issued as U.S. Pat. No.10,842,517 on Nov. 24, 2020; U.S. application Ser. No. 15/934,148,entitled “Seal for Surgical Instrument,” filed on Mar. 23, 2018,published as U.S. Pub. No. 2019/0290308 on Sep. 26, 2019, issued as U.S.Pat. No. 10,799,257 on Oct. 13, 2020; U.S. application Ser. No.15/934,160, entitled “Surgical Instrument with Recessed Contacts andElectrically Insulting Barriers,” filed on Mar. 23, 2018, published asU.S. Pub. No. 2019/0290269 on Sep. 26, 2019, issued as U.S. Pat. No.11,026,681 on June 8, 2021; U.S. application Ser. No. 15/934,166,entitled “Surgical Instrument with Electrical Contact Under Membrane,”filed on Mar. 23, 2018, published as U.S. Pub. No. 2019/0290270 on Sep.26, 2019, issued as U.S. Pat. No. 10,631,860 on Apr. 28, 2020; U.S.application Ser. No. 15/934,173, entitled “Staple Cartridge with ShortCircuit Prevention Features,” filed on Mar. 23, 2018, published as U.S.Pub. No. 2019/0290271 on Sep. 26, 2019, issued as U.S. Pat. No.10,639,038 on May 5, 2020; and U.S. application Ser. No. 15/934,180,entitled “Surgical Instrument with Capacitive Electrical Interface,”filed on Mar. 23, 2018, published as U.S. Pub. No. 2019/0290272 on Sep.26, 2019, issued as U.S. Pat. No. 10,779,828 on Sep. 22, 2020.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof any of the following: U.S. Pat. No. 5,792,135, entitled “ArticulatedSurgical Instrument For Performing Minimally Invasive Surgery WithEnhanced Dexterity and Sensitivity,” issued Aug. 11, 1998, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.5,817,084, entitled “Remote Center Positioning Device with FlexibleDrive,” issued Oct. 6, 1998, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,878,193, entitled “Automated EndoscopeSystem for Optimal Positioning,” issued Mar. 2, 1999, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,231,565,entitled “Robotic Arm DLUS for Performing Surgical Tasks,” issued May15, 2001, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool with UltrasoundCauterizing and Cutting Instrument,” issued Aug. 31, 2004, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,364,888, entitled “Alignment of Master and Slave in a MinimallyInvasive Surgical Apparatus,” issued Apr. 2, 2002, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,524,320,entitled “Mechanical Actuator Interface System for Robotic SurgicalTools,” issued Apr. 28, 2009, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,691,098, entitled “Platform Link WristMechanism,” issued Apr. 6, 2010, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 7,806,891, entitled “Repositioningand Reorientation of Master/Slave Relationship in Minimally InvasiveTelesurgery,” issued Oct. 5, 2010, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,844,789, entitled“Automated End Effector Component Reloading System for Use with aRobotic System,” issued Sep. 30, 2014, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,820,605, entitled“Robotically-Controlled Surgical Instruments,” issued Sep. 2, 2014, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.8,616,431, entitled “Shiftable Drive Interface forRobotically-Controlled Surgical Tool,” issued Dec. 31, 2013, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.8,573,461, entitled “Surgical Stapling Instruments with Cam-DrivenStaple Deployment Arrangements,” issued Nov. 5, 2013, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 8,602,288,entitled “Robotically-Controlled Motorized Surgical End Effector Systemwith Rotary Actuated Closure Systems Having Variable Actuation Speeds,”issued Dec. 10, 2013, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 9,301,759, entitled“Robotically-Controlled Surgical Instrument with SelectivelyArticulatable End Effector,” issued Apr. 5, 2016, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 8,783,541,entitled “Robotically-Controlled Surgical End Effector System,” issuedJul. 22, 2014, the disclosure of which is incorporated by referenceherein; U.S. Pat. No. 8,479,969, entitled “Drive Interface for OperablyCoupling a Manipulatable Surgical Tool to a Robot,” issued Jul. 9, 2013;U.S. Pat. Pub. No. 8,800,838, entitled “Robotically-ControlledCable-Based Surgical End Effectors,” issued Aug. 12, 2014, thedisclosure of which is incorporated by reference herein; and/or U.S.Pat. No. 8,573,465, entitled “Robotically-Controlled Surgical EndEffector System with Rotary Actuated Closure Systems,” issued Nov. 5,2013, the disclosure of which is incorporated by reference herein.

Versions of the devices described above may be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Versions may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, some versions of the device may be disassembled, and anynumber of the particular pieces or parts of the device may beselectively replaced or removed in any combination. Upon cleaning and/orreplacement of particular parts, some versions of the device may bereassembled for subsequent use either at a reconditioning facility, orby a user immediately prior to a procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. A slip ring assembly for a surgical instrument having abody and a shaft tube extending distally from and rotatable relative tothe body, the slip ring assembly comprising: (a) an outer contactsupport structure; (b) an inner contact support structure rotatablerelative to the outer contact support structure about an axis, whereinone of the inner contact support structure or the outer contact supportstructure is configured to be rotationally fixed relative to the body,wherein the other of the inner contact support structure or the outercontact support structure is configured to be rotationally fixedrelative to the shaft tube to thereby rotate with the shaft tuberelative to the body about the axis; (c) a plurality of first electricalcontacts spaced apart axially and supported by the inner contact supportstructure; and (d) a plurality of second electrical contacts spacedapart axially and supported by the outer contact support structure,wherein the plurality of second electrical contacts is positionedradially outward of the plurality of first electrical contacts, whereinthe first and second electrical contacts are rotatable relative to eachother about the axis while remaining electrically coupled to each otherfor enabling electrical communication between the shaft tube and thebody while permitting relative rotation therebetween.
 2. The slip ringassembly of claim 1, wherein the outer contact support structureencircles the plurality of first electrical contacts.
 3. The slip ringassembly of claim 1, wherein one of the plurality of first electricalcontacts or the plurality of second electrical contacts comprises aplurality of ring contacts.
 4. The slip ring assembly of claim 3,wherein the other of the plurality of first electrical contacts or theplurality of second electrical contacts comprises a plurality of brushcontacts.
 5. The slip ring assembly of claim 4, wherein each of thebrush contacts includes an angled distal edge, wherein the angled distaledge is configured to promote sliding engagement of the first contactswith the second contacts in a direction parallel to the axis.
 6. Theslip ring assembly of claim 1, wherein the first electrical contacts arespaced apart with non-uniform axial spacing.
 7. The slip ring assemblyof claim 6, wherein the second electrical contacts are spaced apart withnon-uniform axial spacing.
 8. The slip ring assembly of claim 1, whereineach adjacent pair of the second electrical contacts is separated by anelectrically insulating barrier.
 9. The slip ring assembly of claim 8,wherein the electrically insulating barrier is defined by the outercontact support structure.
 10. The slip ring assembly of claim 8,wherein the electrically insulating barrier comprises an electricallyinsulating element coupled to the outer contact support structure. 11.The slip ring assembly of claim 1, wherein one of the outer contactsupport structure or the inner contact support structure includes acontact sleeve.
 12. The slip ring assembly of claim 1, wherein one ofthe outer contact support structure or the inner contact supportstructure includes a contact block.
 13. The slip ring assembly of claim1, wherein one of the first contacts or the second contacts include apair of high-power contacts each having a first axial width and a pairof low-power contacts each having a second axial width smaller than thefirst axial width.
 14. The slip ring assembly of claim 13, wherein thehigh-power contacts are spaced apart by a first axial distance and thelow-power contacts are spaced apart by a second axial distance smallerthan the first axial distance.
 15. The slip ring assembly of claim 14,wherein each of the low-power contacts is spaced apart from an adjacenthigh-power contact of the pair of high-power contacts by a third axialdistance greater than the second axial distance and smaller than thefirst axial distance.
 16. A surgical instrument, comprising: (a) a bodyassembly; (b) a shaft assembly extending distally from the body assemblyalong a shaft axis, wherein the shaft assembly includes a shaft tubeconfigured to rotate relative to the body assembly about the shaft axis;(c) an end effector at a distal end of the shaft assembly, wherein theend effector is operable to treat tissue; and (d) a slip ring assemblyconfigured to enable electrical communication between the shaft assemblyand the body assembly while permitting relative rotation therebetween,wherein the slip ring assembly comprises: (i) a plurality of firstcontacts spaced apart axially along the shaft axis, and (ii) a pluralityof second contacts spaced apart axially along the shaft axis, whereinthe second contacts encircle and electrically couple with the firstcontacts, wherein one of the first contacts or the second contacts areconfigured to rotate with the shaft tube about the shaft axis relativeto the other of the first contacts or the second contacts while thefirst contacts and the second contacts remain electrically coupled. 17.The surgical instrument of claim 16, wherein the first contacts and thesecond contacts are configured to electrically engage at a locationradially outward of the shaft tube.
 18. The surgical instrument of claim16, wherein the first contacts are supported by the shaft tube, whereinthe second contacts are supported by a sleeve that encircles the shafttube.
 19. A surgical instrument, comprising: (a) a body assembly; (b) ashaft assembly extending distally from the body assembly along a shaftaxis, wherein the shaft assembly includes a shaft tube configured torotate relative to the body assembly about the shaft axis; (c) an endeffector at a distal end of the shaft assembly, wherein the end effectoris operable to treat tissue; and (d) a slip ring assembly configured toenable electrical communication between the shaft assembly and the bodyassembly while permitting relative rotation therebetween, wherein theslip ring assembly comprises: (i) a plurality of first contacts arrangedaxially, wherein the first contacts are spaced apart with non-uniformaxial spacing, and (ii) a plurality of second contacts arranged axiallyand configured to electrically couple with the first contacts, whereinone of the first contacts or the second contacts are configured torotate with the shaft tube about the shaft axis relative to the other ofthe first contacts or the second contacts while the first contacts andthe second contacts remain electrically coupled.
 20. The surgicalinstrument of claim 19, wherein the second contacts are spaced apartwith non-uniform axial spacing, wherein the non-uniform axial spacing ofthe second contacts is configured to establish impedances that preventelectrical shorting between non-coupled pairs of the contacts in thepresence of fluid.